DIY Network

Headliner Repair: Board Repair and Fabric Replacement From "Weekend Mechanic" episode WKM-302

In this segment, Weekend Mechanic host Bruce Bonebrake begins work uncovering and repairing the damaged headliner board, and re-covering it with new headliner fabric.

Important: Included below are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Materials:

Standard mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, etc.)
Replacement headliner material
Soft-bristle brush
Glue gun and
Spray-on automotive-grade contact adhesive
Duct tape
Razor knife
Scissors
Respirator mask
Eye protection

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Repairing a Damaged Headliner Board

Since our headliner board broke apart upon removal to fix a sagging headliner, repair to the board would be required. According to auto-interior expert Tony Fleming, this situation is not uncommon since sun and heat damage typically causes headliner boards to become brittle and increasingly fragile over time. Many are simply made from a pressed-cardboard material. However, in our case Tony determined that the damage to this board was repairable.

• Begin by scrubbing all of the old foam and glue from the headliner board using a soft-bristle brush (figures A and B). This step is critical to repair of the old board since the new covering will need a clean surface to adhere to. Without a good attachment, a new covering will sag just as the old one did.

  Important: Avoid using a wire brush. It may tear the headliner board.

  Important: Never use a chemical glue-remover to clean old adhesive from a headliner board.

  Figure A

  Figure B

  
  

  	Figure C
  	Figure D
  	Figure E

• The repair begins of the back (underneath) side of the headliner board. Lay the broken pieces out onto a flat surface to align them (figure C).

• Use caution when aligning the pieces to avoid overlapping the edges. Creases left from overlapping will show through the new fabric.

• You can use ordinary duct-tape to join the cracks where the pieces join together (figure D). Double-tape all of the cracks to ensure a secure repair.

  Important: Avoid using duct tape on the interior side of the board, as it will leave a crease in the headliner fabric.

• Trim away any the excess duct tape along the edges using a razor knife (figure E).

• Repeat these steps to repair all of the damaged areas.

• Once all of the parts of the headliner board have been joined together securely, carefully flip the board back over. You're now ready to apply the new fabric cover.

• The fabric covering comes with a cloth side and a foam side. You'll need to have a piece of fabric slightly larger than the headliner board so that the edges of the fabric hang over the board on all sides.

• It's easiest to glue the fabric onto the board one half at a time.
  

  	Figure F
  	Figure G

• Important: Use only a spray adhesive specially formulated for use with auto trim. This type of glue is made to withstand extremes of heat and cold and continue to hold its bond.

• Safety Alert: Always work in a well ventilated area when working with spray paint, glues, solvents or other hazardous chemicals.

• The contact adhesive should be applied with a glue sprayer to the surface of the board (figure F) and to the foam side of the fabric covering. Using the sprayer, apply an even coat of glue.

  The bond forms when the two surfaces are brought together, and the glue achieves optimum tackiness for bonding about 30 seconds after spraying. Once the glue has been sprayed onto both surfaces, carefully lift and position the fabric, allowing it to drape over the edges of the board (figure G). Smooth the fabric down onto the board, beginning at the center and working your way outward.
  
  

• Repeat the process, spraying the foam surface of the cloth and the board surface, on the other half. Once that application of glue has set up and is tacky, drop the other half of the fabric into position (figure H) and press the fabric lightly to smooth it and glue it down (figure I). Avoid pressing down heavily onto the fabric as this may force the glue to the surface.

  Figure H

  Figure I

  
  

  	Figure J
  	Figure K

• With the headliner fabric in place and properly contoured, you can flip the headliner board over (figure J) to trim the excess fabric from the edges.

• Start by cutting around the outside, leaving an inch or so of overlap. Then cut an opening for the sunroof (figure K).

• Use your scissors to punch holes in the fabric in the appropriate locations for the visors and mirror.

• Fold the overlap along the edges and glue it down along the front and back (figure L).
  

  	Figure L
  	Figure M
  	Figure N
  	Figure O

  
  
• This sunroof panel, is consists of two pieces that will be covered separately. Begin by peeling off the old fabric covering the panels (figure M). This may be more difficult to remove than the fabric that was covering the headliner but the glue is easier to remove and cleanup is quicker.

  Important: A commercial grade automotive contact cement will be required to bond the fabric to the metal frame.

• The headliner material is attached to the sunroof panel by gluing only the edges of the sunroof panel, and not the backside of the panel.

• Once the glue has been applied, stretch the fabric tightly over the panel to make the fabric thinner. This will make the sunroof headliner slide more easily and fit better. Fold the material over the edges and press the fabric down (figure N). This side of the panel will not be visible once the panel is installed, so it won't matter if the glue bleeds through the fabric in these locations when pressed down.

• Once the glue has set, cut an opening for the vent and trim away the excess (figure O). Fold over any remaining overlap and glue it down tight.

• Repeat the steps for the other portion of the sunroof panel. Remember that glue only needs to be applied so that the edges are secured on the underneath side of the panel -- unlike the gluing process used earlier for the headliner board.
  
  
• With the sunroof removed, it's a good time to check some of the operating components such as the drains and motor. On this vehicle, the drains connect to four separate water hoses (figure P) that drain the water away and out of the car. Check the drains to ensure that they are not clogged, and check the hoses and clamps to make sure they are in good order. Also check the drain troughs to ensure that they are not blocked with debris.

• Check to see if your sunroof mechanism needs lubrication. Since our vehicle has a power sunroof, we took this opportunity to check the electric motor and wiring (figure Q). If your power sunroof motor is dragging or causing problems, this would be a good time to replace it.

  Figure P

  Figure Q

  
  

RESOURCES :

The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books

Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896

Automotive Detailing: A Complete Car Care Guide for Auto Enthusiasts and Detailing Professionals
1557882886
Don Taylor
To order this title from Amazon, click here.
H.P. Books